Welcome

POWER PLANT C&I

Dr.R.JayapalT&D

Training program for Marketing Managers

19-04-2011

POWER PLANT AUTOMATIONPOWER PLANT AUTOMATION

PRESENT DAY POWER PLANTS ARE HUGE AND COMPLEX

HUGE NUMBER OF PARAMETERS / SIGNALS ARE BEING ACQUIRED, ANALYSED AND DISPLAYED IN OPERATOR WORK STATION AND AS WELL IN MANAGEMENT INFORMATION SYSTEM (MIS)

IT BECOMES VERY DIFFICULT FOR THE OPERATOR TO HANDLE SUCH HUGE INFORMATION SPECIALLY DURING EMERGENCIES AND TO TAKE QUICK AND CORRECT DECISION AND ACT FAST

POWER PLANT AUTOMATIONPOWER PLANT AUTOMATION

AUTOMATION IS ESSENTIALLY REQUIRED FOR TIMELY AND CORRECT PLANT OPERATION.

TO RELIEVE THE OPERATOR FROM DECISION MAKING AND TO CONCENTRATE ON MONITORING THE PLANT OPERATION AND CRITICAL PARAMETERS

LARGER THE SIZE OF MACHINE, HIGHER THE DEGREE OF AUTOMATION.

TYPES OF CONTROLSTYPES OF CONTROLS

CLOSED LOOP CONTROLBINARY CONTROL SEQUENCE CONTROLDRIVE CONTROLINTER LOCK AND PROTECTION

POWER PLANT CRITICAL POWER PLANT CRITICAL CLOSED LOOP CONTROLSCLOSED LOOP CONTROLSCOMBUSTION CONTROLDRUM LEVEL CONTROLFURNACE DRAUGHT CONTROLSTEAM TEMPERATURE CONTROLDEAERATOR PRESSURE / LEVEL CONTROLPRDS CONTROLHEATERS LEVEL CONTROLHOTWELL LEVEL CONTROLTURBINE GLAND STEAM PRESSURE AND TEMP.

CONTROL

POWER PLANT CRITICAL DRIVE POWER PLANT CRITICAL DRIVE CONTROLSCONTROLSID, FD, & PA FAN CONTROLFEED PUMP CONTROLFUEL FEEDER CONTROLCOOLING WATER PUMP CONTROLMAIN STEAM STOP VALVE MOTORISED VALVE CONTROLCEP MOTOR CONROL etc.,

SEQUENCESSEQUENCES

• FUEL HANDLING SYSTEM SEQUENCEFUEL HANDLING SYSTEM SEQUENCE• ASH HANDLING SYSTEM SEQUENCEASH HANDLING SYSTEM SEQUENCE• WATER TREATMENT PLANT UF CYCLE / WATER TREATMENT PLANT UF CYCLE /

RO CYCLE SEQUENCERO CYCLE SEQUENCE

INFORMATION SYSTEM

PLANT OVERVIEW DISPLAYPLANT SCHEMATICS / GRAPHICSBAR CHART DISPLAYTREND DISPLAYALARM DISPLAYLOOP DISPLAYLOGS & REPORTS ETC.SEQUENCE OF EVENT RECORDING

DISTRIBUTED CONTROL SYSTEM

(DCS)

BOILER BOP

TURBINE

POWER

AUXILLIARIES ELECTRICAL

OUTSIDEWORLD

Distributed control system (DCS)- Functionally & Geographically distributed digital control

- DCS introduced in 1975 by Honeywell and Yokogawa around same time

- DCS Components :

- Input Modules - Output Modules - Controllers - Network Modules - Network Switches/Hubs - Time Synchronisation System - Operator / Engineer Stations - OPC Stations - History Server - Printers - Large Video Screens - Power Supplies - UPS - Software like OS , HMI Configuration etc

DCS ModulesInput Module :

- 4 – 20 mA / 0 – 20 mA / 0 – 10 V Module - Thermocouple Module - RTD Module - Digital Input

Output Module :

- 4 – 20 mA / 0 – 20 mA / 0 – 10 V Module - Relay Module ... - Digital Output Module

SOE Modules

HART / Profibus / Foundation Field bus / Modbus Modules

Distributed control system (DCS)

Networking Technologies. . . . . . . . .

- Profibus

- Modbus

- Foundation Field bus

- CAN Bus

Other Technologies. . . . . . . . .

- HART

- OPC (OLE for Process control )

`Distributed control system (DCS)

Vibration monitoring &

Governor control

P R O C E S S

System Bus (Red)

OS-1

19”

OS-2

19”

MODBUS Gateway interface

DMP CGP

I/Os

Redundant Controller

Boiler, TG,

FHS,&

others

ES/OS

19”

DCS SYSTEM CONFIGURATION

19”

OS-3

LEVEL-1

LEVEL-2

LEVEL-3

LEVEL 1LEVEL 1

• THIS IS A SUPERVISORY LEVELTHIS IS A SUPERVISORY LEVEL• ENGINEERING AND OPERATATIONAL ENGINEERING AND OPERATATIONAL

ACTIVITES ARE DONE IN THIS LEVELACTIVITES ARE DONE IN THIS LEVEL• ENGINEERING ACTIVITES LIKE ENGINEERING ACTIVITES LIKE

DEVELOPING NEW DRIVE LOGIC, GRAPHIC DEVELOPING NEW DRIVE LOGIC, GRAPHIC PAGE DEVELOPMENT, PID CONTROLLER PAGE DEVELOPMENT, PID CONTROLLER TUNING etc.,TUNING etc.,

• OPERATOR ACTIVITIES LIKE OPERATOR ACTIVITIES LIKE MONITORING, ON/OFF OF DRIVES etc.,MONITORING, ON/OFF OF DRIVES etc.,

LEVEL 2LEVEL 2• THIS IS A NETWORK LEVEL OR THIS IS A NETWORK LEVEL OR

COMMUNICATION LEVELCOMMUNICATION LEVEL• NUMBER OF CONTROLLERS ARE NUMBER OF CONTROLLERS ARE

CONNECTED TOGETHER AND ACCESSED CONNECTED TOGETHER AND ACCESSED BY HMI STATIONSBY HMI STATIONS

LEVEL 3LEVEL 3

• THIS IS A FIELD LEVELTHIS IS A FIELD LEVEL• SIGNAL FORM FIELD INSTRUMENTS ARE SIGNAL FORM FIELD INSTRUMENTS ARE

GIVEN TO IO MODULESGIVEN TO IO MODULES• IO MODULES CONVERT THE RAW SIGNAL IO MODULES CONVERT THE RAW SIGNAL

IN TO CONTROLLER UNDERSTANDABLE IN TO CONTROLLER UNDERSTANDABLE DIGITAL FORMATDIGITAL FORMAT

• CONTROLLERS TAKE DECESION CONTROLLERS TAKE DECESION ACCORDING TO THE LOGIC PROGRAMMED ACCORDING TO THE LOGIC PROGRAMMED

SIGNAL COMMUNICATION STAGESIGNAL COMMUNICATION STAGE

MARSHALLING TB

I/O MODULES

COMMN.CARD

CONTROLLER

FIELD

ETHERNETSWITCH

OS ES

THIRD PARTY DEVICE THIRD PARTY DEVICE COMMUNICATIONCOMMUNICATION

• MODBUS RTU (RS 485) TO INTER MODBUS RTU (RS 485) TO INTER CONNECT STAND ALONE PLCS, RELAYS, CONNECT STAND ALONE PLCS, RELAYS, MULTIFUNCTION METER etc., MULTIFUNCTION METER etc.,

• PROFIBUS – DRIVES INTERFACINGPROFIBUS – DRIVES INTERFACING• OPC – MANAGEMENT INFORMATION OPC – MANAGEMENT INFORMATION

SYSTEM CONNECTIVITY TO TRANSFER SYSTEM CONNECTIVITY TO TRANSFER THE REPORTS (OLE FOR PROCESS THE REPORTS (OLE FOR PROCESS CONTROL)CONTROL)

STANDARD MANUFACTURERS

1. Honeywell

2. Emerson

3. ABB

4. Siemens

5. Yokogawa

6. Invensys

7. Supcon , China

8. GE

9. Alstom Distributed control system (DCS)

WHAT IS “PLC” ?WHAT IS “PLC” ?

PROGRAMMABLE LOGIC

CONTROLLER

FIELD INSTRUMENTSFIELD INSTRUMENTS1. Pressure transmitter1. Pressure transmitter - Capacitance type- Capacitance type - Piezo resistive type- Piezo resistive type - Typical vendors : Emerson , ABB- Typical vendors : Emerson , ABB2. Temperature sensor2. Temperature sensor - Thermocouple (K,T,R type)- Thermocouple (K,T,R type) (K Type – chromel – Alumel )(K Type – chromel – Alumel ) - Resistance Temperature Detector(RTD) (PT100)- Resistance Temperature Detector(RTD) (PT100) - Typical vendors : General Instruments , Nagman, - Typical vendors : General Instruments , Nagman,

several small /medium scale manufacturers several small /medium scale manufacturers

FIELD INSTRUMENTSFIELD INSTRUMENTS3. Flow Elements / Flow meters3. Flow Elements / Flow meters (a) orifice assembly(a) orifice assembly - Flange tapping- Flange tapping - Corner tapping- Corner tapping - D,D/2 tapping- D,D/2 tapping - High pressure water flow measurements - High pressure water flow measurements - Typical vendors : IL/P, MIL/P ,CVL shop.- Typical vendors : IL/P, MIL/P ,CVL shop. (b) Flow Nozzle / Venturi(b) Flow Nozzle / Venturi - Less pressure drop- Less pressure drop - For steam flow- For steam flow - Aerofoil for airflow in duct - Aerofoil for airflow in duct - Typical vendors: IL/P, MIL/P- Typical vendors: IL/P, MIL/P

FIELD INSTRUMENTSFIELD INSTRUMENTS3. Flow Elements / Flow meters3. Flow Elements / Flow meters (c) Magnetic Flow meter(c) Magnetic Flow meter - Works on Faraday's Law- Works on Faraday's Law - No pressure drop, suitable for low pressure - No pressure drop, suitable for low pressure

water lines water lines - Not suitable for DM water as it needs minimum - Not suitable for DM water as it needs minimum

conductivity of > 45 conductivity of > 45 µs/cmµs/cm - PTFE coating on electrode for medium - PTFE coating on electrode for medium

temperature up to 175 temperature up to 175ºcºc - Elastomer coating on electrode for medium - Elastomer coating on electrode for medium

temperature up to 70 temperature up to 70ºcºc - Typical vendors: ABB , Emerson- Typical vendors: ABB , Emerson

FIELD INSTRUMENTSFIELD INSTRUMENTS3. Flow Elements / Flow meters3. Flow Elements / Flow meters (d) Vortex Flow meter(d) Vortex Flow meter - Medium temp up to 400- Medium temp up to 400ºcºc - DM water application- DM water application - Typical vendors : - Typical vendors : (e) Positive displacement (PD) flow meter(e) Positive displacement (PD) flow meter - also called oval wheel meter- also called oval wheel meter - for HFO/Diesel/LFO application- for HFO/Diesel/LFO application - Typical vendors: - Typical vendors:

Toshniwal,Bopp&Reuther,GERMANY. Toshniwal,Bopp&Reuther,GERMANY.

FIELD INSTRUMENTSFIELD INSTRUMENTS3. Flow Elements / Flow meters3. Flow Elements / Flow meters (f) Turbine Flow meter (f) Turbine Flow meter - - Less ExpensiveLess Expensive - suitable for water flow- suitable for water flow

(g) Variable Area Flow meter with magnetic follower (g) Variable Area Flow meter with magnetic follower - Water / Air flows- Water / Air flows - used in compressor discharge airline- used in compressor discharge airline

AnalysersAnalysers (a) STACK Analysers (CEMS - Continuous Emission (a) STACK Analysers (CEMS - Continuous Emission

Monitoring System) Monitoring System) - Sample extraction type, in-situ type- Sample extraction type, in-situ type - SOx , NOx, co,co2 , SPM (Suspended - SOx , NOx, co,co2 , SPM (Suspended

Particulate Matter) Particulate Matter) - Typical vendor: Emerson , Fuji (Analyser - Typical vendor: Emerson , Fuji (Analyser

instruments) , Chemtrols instruments) , Chemtrols (b) Zirconia probe(b) Zirconia probe - - Oxygen measurement in Eco outletOxygen measurement in Eco outlet - Typical vendor: Emerson , Forbes Marshall- Typical vendor: Emerson , Forbes Marshall

AnalysersAnalysers

(c) Steam & Water Analysers (SWAS)(c) Steam & Water Analysers (SWAS) - wet panel + Dry panel- wet panel + Dry panel - PH , Conductivity ,Dissolved oxygen, - PH , Conductivity ,Dissolved oxygen,

Hydrazine,Silica in water. Hydrazine,Silica in water. - - Feed water line, Continuous Blow down tank , Feed water line, Continuous Blow down tank ,

Superheated steam, Deaerator outlet , Hot Superheated steam, Deaerator outlet , Hot well outlet well outlet

- Typical vendor: Emerson , ABB- Typical vendor: Emerson , ABB

Special InstrumentsSpecial Instruments

1. Flame Scanner1. Flame Scanner 2. Hydrastep drum level indicator2. Hydrastep drum level indicator 3. Conductivity type level switch3. Conductivity type level switch 4. High Energy Arc Ignitor4. High Energy Arc Ignitor 5. Vibration monitoring system5. Vibration monitoring system 6. Annunciator.6. Annunciator.

Scanner head and installation drawing

Wavelength figure

Flame signal pattern

STANDARD VENDORS – FLAME SCANNERS

1. ABB

2.COEN , USA

3.Fire eye , USA

4.Durag , Germany

5.Hameworthy Peabody

6.BHEL

Electronic water Level Indicator (EWLI)

- Drum water Level monitoring

- Based on conductivity principle (Water conductivity >> Steam conductivity)

- Normally drum level monitored in 12 steps (For 500MW Boiler – 16 steps)

- Conductivity probes(Electrodes) installed in sampling pressure vessel

- For utility boilers, two equipments (Left,Right) used

- EWLI equipment provides. - Water / Steam Display by Green / Red LED's - 3 Display units (Drum Floor, Fireman Floor, Control Room) - High Trip, High Alarm , Low Alarm , Low Trip Contacts - 4-20mA Current output - Modbus Communication

- CVL EWLI is named CETLEV

Electronic water Level Indicator (EWLI)

Conductivity graph

EWLI INSTALLATION

Electronic water Level Indicator (EWLI)

ELECTRODE

BLANKING PLUG

INSERT

Electronic water Level Indicator (EWLI)

STANDARD VENDORS – EWLI

1. Solartron Mobrey , UK

2.Yarway , USA

3.Levelstate , USA

4.BHEL

5.CVL ?

Electronic water Level Indicator (EWLI)

Conductivity type level switch- HP/ LP Heater , Deaerator , Hot well,condensing Pot Level monitoring.

- Based on conductivity principle .

- No moving part to fail. Hence more reliable compared to conventional float switches

- All levels using one stand pipe , Hence compact Layout

- 2 Channel & 4 Channel version available

- CVL conductivity level switch named 'CETMHO'

TYPICAL CONDUCTIVITY TYPE LEVEL SWITCH INSTALLATION

Conductivity type level switch

Conductivity type level switch

STANDARD VENDORS – Conductivity type level switch

1. Solartron Mobrey , UK

2.Yarway , USA

3.Levelstate , USA

4.Clarke reliance , UK

5.BHEL 6.CVL ?

Conductivity type level switch

High Energy Arc (HEA ) Igniter- HEA Assembly consists of - Excitor Box - Retractory assembly (SV operated power cylinder) - Spark rod ,Spark tip/ spark plug

- Capable of lighting LFO / HFO directly - Pulsed electric arc system

- Voltage given to spark plug – 2500 to 3000 V DC

- Spark energy – 12 Joules Nominal

- Spark Rate – 4 to 10 per second

- Flame scanner monitors oil flame during HEA igniter operation (A few seconds). If flame is not detected , BMS trips the oil gun.

- Two types - Conventional HT transformers , Spark gap type - Solid State type.

HEA PARTS

High Energy Arc (HEA ) Ignitor

STANDARD MANUFACTURERS

1. DURAG

2. BHEL

3. COEN

4.Forney

5. Many small scale manufacturers in India like Asba , Trichy ; Nesam , Delhi ; Hindustan Thermometer , Delhi ; Mint , Delhi

High Energy Arc (HEA ) Ignitor

Vibration Monitoring systemVibration Monitoring system

- Proximity type displacement sensor / Piezo - Proximity type displacement sensor / Piezo electric type accelerometer. electric type accelerometer.

- Vibration transmitter / sensor + processing unit- Vibration transmitter / sensor + processing unit - Single / Multiple channel- Single / Multiple channel - PC based vibration analyser- PC based vibration analyser - Bearing vibration in HT drives like ID/FD/PA fans- Bearing vibration in HT drives like ID/FD/PA fans